Moisture-resistant floor tile covering system for concrete floors

ABSTRACT

A thermally insulating tile floor covering system comprising a water resistant, inorganic, thermal air-gap plastic barrier tile layer which is provided with a network of integral spaced plastic studs, legs or wall sections on the underside thereof, to form an interconnected space network between the undersurface of the flat plastic tile and the surface of a concrete floor supporting the tile. The space network provides an insulating thermal air gap barrier space to receive and circulate any water vapor penetrating up through the concrete floor.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an improved system for protectingfinished flooring over on-grade concrete floors from damage from watervapor penetration and for insulating them from the cool earthtemperatures. Concrete floors particularly concrete floors installed orpoured over the dirt surfaces of sub-terrainean rooms such as basementliving spaces of homes or the ground-level rooms or work spaces ofslab-homes or buildings, are particularly susceptible to water vaporpenetration. Conventionally, such concrete floors are covered withplastic tiles or carpeting to improve their appearance and make themmore comfortable to the feel.

However, concrete floors are relatively porous and also conduct the coldtemperature of the ground, which can result in water vapor penetrationand condensation at the interior surface of the concrete floor, causingseparation of floor tiles adhered thereto or causing a moistureaccumulation in carpeting adhered thereto or applied thereover,resulting in mold or mildew. Water vapor and water can penetrate anddiffuse through the porous concrete floor from the dampness of the soilor ground beneath the concrete, and also through cracks which candevelop in the concrete and/or also can penetrate through interfacesbetween the floor and the walls and/or footings.

2. State of the Art

It is known to build a sub-floor over concrete floors using wooden studsas spacers and covering them with plywood to form an interior floorsurface which is then covered by floor tile or carpeting. Such a systemis an insulation improvement, but takes up to 2″ of headroom or more.Water vapor can be absorbed by the wooden studs and plywood, resultingin mold, mildew, rot and odors, and separation of tiles from the plywoodfloor.

An improved flooring system is commercially-available from applicant'scompany, Basement Systems, Inc., under the trademark ThermalDry®Flooring System. Such system involves interposing an embossedinsulating, thermal air-gap, high density plastic barrier sheet betweenthe concrete floor and a plywood or chipboard floor, the barrier sheetbeing embossed to form rear-surface projections and front surfacedepressions, to space the concrete floor from the plywood or chipboardfloor. The ThermalDry® Flooring System produces excellent results buthas the disadvantage that it still incorporates a plywood or chipboardfloor, which can absorb water or water vapor which might penetrate frombelow the plywood or from above the plywood, due to plumbing leaks orflooding. In addition to ground water vapor, water heater leaks andplumbing leaks are common and this water ends up on the basement floor.Therefore, it is imperative to install an insulating flooring systemthat uses no organic materials. Plywood and chipboard absorb water andwater vapor which can cause them to swell and delaminate and can supportmold, requiring complete replacement of the flooring system. Anotherimportant disadvantage of this system and of systems such as disclosedin U.S. Pat. Nos. 5,052,161; 5,489,462 and 5,619,832 is that an embossedplastic barrier sheet does not have a solid, planar or flat uppersurface to support a carpet as an outer covering, if desired.

Another flooring system is commercially-available for the insulation ofconcrete basement floors, comprising 24″ square wood tiles having bondedto the undersurface thereof a backing layer of water-resistant plasticmolded with a plurality of spaced water-resistant studs or spacers whichprovide an air gap between the concrete floor and the wood tiles. Suchsystem is unsatisfactory since the wood tiles, formed from “chipboard”,warp and delaminate in the moist atmosphere and/or when wet from above,and support mold and the consequences thereof. Water vapor can penetratefrom the porous concrete up through the joints between the wood tilesand the plastic backings and be absorbed, causing swelling of the wood,particularly along the joints. Also a water leak or flood in thebasement can saturate the wooden tiles and also can penetrate betweenthe tiles and under the plastic backing, making it impossible to dry orremove the water without ripping up the floor.

SUMMARY OF THE INVENTION

The present invention relates to a water-resistant flooring system forinsulating against dampness and cold penetration from concretesub-floors, and which will not be damaged by water penetration from anydirection or source, including above-floor plumbing problems orflooding.

The present flooring system comprises a thermally-insulatingwater-vapor-proof, air-gap, solid plastic barrier tile layer systemcomprising a strong rigid flat solid layer of water-resistant plastic,such as ABS, polyvinyl chloride, polyethylene, polypropylene orpolycarbonate, which is either molded with integral spaced plastic legsor spacers such as studs or slots or other raised areas on the undersidethereof, or is laminated or bonded to a separate water-resistant solidplastic barrier sheet which is molded with integral spaced plastic legsor spacers such as studs or slots or other raised and/or depressed areason the underside thereof, to provide spaced leg portions which contactthe surface of the concrete floor and which space and support theunderside of the flat plastic tile from the surface of the concretefloor to provide an insulating thermal air gap barrier space betweenabout ⅛″ and 1″ high, preferably about {fraction (3/8)} inch high, toadmit and circulate any water vapor penetrating up through the concretefloor beneath the entire barrier tile layer system. The air gap barrierspace provides a space network within which the water vapor circulatesand comes into equilibrium with the water content of the porous concretefloor. Water condensation, which will occur if you lay a flat sheet ofplastic against a concrete floor, is avoided or substantially reduced bythe present plurality of spacers which create the air gap barrier space.Water vapor from the concrete floor cannot condense within the air gap,and humid air from the basement living space cannot penetrate theinterlocked plastic tiles to condense on the concrete floor.

The flat plastic barrier tile layer preferably comprises a plurality ofsquare or rectangular solid tiles, such as 6″, 12″, 17″, 24″ square or48″ or even 4′×8′ rectangular sheets, about ⅜″ to ¾″ thick, which fit orinterlock together such as with tongue-and-groove sides like parquetflooring. As mentioned, the plastic tiles may be formed or molded withthe spaced legs or studs on the underside thereof. The top surfaces ofthe solid plastic tiles are planar and may have a decorative designformed thereon, or the planar upper surface of the plastic barrier tilelayer may have a color which is aesthetic, or the tile layer may beafter-covered with a conventional ceramic or plastic tile layer or withcarpeting or a vinyl surface such as linoleum or vinyl flooring.

DRAWINGS

FIG. 1 is a perspective view of the undersurface of a section of amoisture-resistant floor tile for covering a concrete floor, such as abasement floor;

FIG. 2 is a plan view of the uppersurface of a complete floor tile ofthe type illustrated by FIG. 1, showing the network of spaced, raisedwater-resistant studs or legs at the undersurface thereof by means ofbroken lines;

FIG. 3 is a cross-sectional view of the floor tile of FIG. 2 taken alongthe line 3-3 thereof;

FIGS. 4(a) and 4(b) are isometric and plan views, respectively,illustrating the use of spaced integral studs having rectangularcross-sections;

FIGS. 5(a) and 5(b) are views corresponding to FIGS. 4(a) and 4(b) butillustrating the use of spaced integral studs having open squarecross-sections, and

FIGS. 6(a) and 6(b) are views corresponding to FIGS. 5(a) and 5(b) butillustrating the use of spaced integral studs having open tubularcircular shapes having slots.

DETAILED DESCRIPTION

Referring to FIG. 1, the underside 11 of a corner section of a solidwater-resistant plastic floor tile 10 is illustrated, the tile 10 havinggroove or slot means 12 along two edges thereof and tongue means 13along the other two edges, as shown in FIGS. 2 and 3, for mating withcorresponding complementary means on adjacent tiles to lock the tiles toeach other and produce a substantially-continuous, smooth plastic floorsurface which is water impervious.

The plastic tile 10 of FIGS. 1 to 3 is molded to have integral spacedplastic support studs or legs or wall sections 15 projecting a maximumdistance from the underside 11 thereof, and intermediate plastic networksections 16 of intermediate height. The legs or wall sections 15 projectdown a uniform distance to contact the concrete floor 11, a distance ofabout {fraction (5/16)}″, to form an interconnected insulation airspaceimage network 17 between the upper surface of the concrete floor and theunderside of the network sections 16 of the tile 10, which airspacenetwork 17 is continuous and open, and provides a thermal break andreservoir for water vapor which may enter.

As previously disclosed, the present plastic tiles 10 preferably aremolded as a unitary plastic tile element, or plastic tiles can be formedwith planar upper and lower surfaces and thereafter a plurality ofindividual plastic studs or spacers and network walls, similar to 15 and16 in FIG. 1, can be adhered to the planar lower tile surface 11.

An essential requirement is that the studs or legs or wall sections 15are spaced from each other to provide therebetween an interconnectedairspace network such as 16 and 17 shown in FIG. 1 to prevent watervapor passing up through the floor from being isolated in any chamberscreated by the tile legs or standoffs 15, so that said water vapor doesnot condense into water under the tile 10. In addition, thisinterconnected airspace 17 under the plastic floor tile will allow thedrying of any water that may temporarily collect under the tiles, suchas water from an above-floor plumbing leak, water heater leak, etc. orwater from a periodic groundwater leak such as from the floor-wall jointof the foundation. Any collected water vapor is isolated from anyorganic material by which it can be absorbed, such as wood which whenwet nourishes the growth of mold. The isolated water vapor willeventually come into equilibrium with the water vapor content of theconcrete floor. Another embodiment of the invention is an option to ventthe space 17 between the concrete floor surface and the underside of thetiles. This can be done passively at the edge of the floor or activelywith a fan to blow air under or to drawn air from under the floor andexhaust it into the interior room or outside of the building to dry thespace under the floor either continuously or only when necessary.

Referring to FIGS. 4(a) and 4(b), 5(a) and 5(b), and 6(a) and 6(b),these figures illustrate just some of the possible cross-sections forspaced studs or legs 18/19/20 which can be used in association withintermediate network sections 16 and in place of the studs 15 of thewater-resistant plastic tile layer 10 of FIGS. 1 to 3.

The studs 18 of FIGS. 4(a) and 4(b) are rectangular in cross-section andin staggered or offset rows, relative to adjacent rows, as shown.

The studs 19 of FIGS. 5(a) and 5(b) are hollow notched squares incross-section and in staggered rows, as shown, and the studs 20 of FIGS.6(a) and 6(b) are circular in cross-section, similar to studs 15 of FIG.2, but are hollow and have an opening 21 giving them the appearance of araised letter “C”. The studs 19 and 20 are notched to permit water vaporcirculation from within the hollow interiors thereof.

The studs 15, 18, 19 and 20 may have any desired height such as ⅛″ up toabout 1″, most preferably about ⅜″ and are closely spaced and staggeredin rows, as shown, for maximum tile support and stability.

FIG. 7 illustrates a plastic tile board 21 which may be in the form of a17 inch square tile board having opposed tongue and groove edges. Theundersurface comprises a gridwork of repeating raised square outlines 22or studs or stand-offs which contact the concrete basement floor as dothe plurality of raised diagonal “X” studs 23, one within each raisedsquare outline 23. This design provides a multiplicity of insulationaerospaces 24 between the underside of the tile board 21 and the surfaceof the concrete basement floor over which is laid and held in place bythe tongue-and-groove engagement.

The preferred tiles 10 for use according to the present invention, asillustrated by FIGS. 1 to 3 of the drawings, have a solid planar uppersurface 14 and a discontinuous under surface comprising spaced supportstuds or legs and wall sections 15 which project a maximum uniformdistance from the undersurface 11 of the tile 10 to contact thesupporting surface, such as a concrete basement floor. The undersurface11 also comprises spaced intermediate network sections 16 which projecta lesser distance from the undersurface 11 of the tile 10 and do notcontact the surface of the supporting floor. The space therebetweenenables any water vapor which enters from the concrete floor tocirculate through the airspace 17 network beneath the tiles and comeinto equilibrium with the water vapor content of the concrete floor.

The tile design of FIGS. 1 to 3 comprises horizontal walls and verticalwalls 15 which intersect to form square compartments enclosing diagonal,intermediate height, X-shaped walls 16 and a central post or support leg15 of maximum height corresponding to the height of the horizontal andvertical walls 15. In order to provide a circulation airspace 17 beneaththe tiles 10 of FIGS. 1 to 3 it is necessary to provide openings orports in the vertical and/or horizontal walls to reduce sections thereoffrom a maximum height 15 to an intermediate height 16 and to enable anywater vapor to circulate or be moved through an air circulation network17 beneath all areas of each tile 10.

Air circulation spaces are provided between adjacent tiles 10 betweenthe groove or slot means 12 along two adjacent edges of each tile, andunder the elongate tongue means 13 along the other two adjacent edges ofeach tile. Referring to FIG. 2 of the drawing, each groove or slot means12 has a maximum height corresponding to the height of the spacers 15 soas to provide therebetween an air port. Also the elongate tongue means13 along the other edges of the tile 10 comprises a plurality of spacedstop support members 25 which limit the extent of entry of the tonguemeans 13 into the slot means 12, provide space between the members 25 toenable the circulation of water vapor beneath the tiles, and makecontact with the basement floor to further support the tile thereon.

The studs 15, 18, 19, 20, 23 and 24 may have any desired height such as⅛″ up to about 1″, most preferably about ⅜″ and are closely spaced andstaggered in rows, as shown, for maximum tile support and stability.

It should be understood that the foregoing description is onlyillustrative of the invention. Various alternatives and modificationscan be devised by those skilled in the art without departing from theinvention. Accordingly, the present invention is intended to embrace allsuch alternatives, modifications and variances which fall within thescope of the appended claims.

1. A moisture-resistant floor tile covering for concrete floorscomprising a plurality of strong, water-resistant plastic floor tileswhich have a solid planar upper surface and can be abutted with eachother to form a water-impervious floor covering over a concrete floor,said tiles having a network or gridwork of spaced raised water-resistantstuds, legs or wall sections projecting from the undersurface of saidtiles for contacting the surface of the concrete floor to provide auniform thermal air gap space network between the undersurface of saidtiles and the surface of said concrete floor in areas intermediate saidplurality of spaced studs, legs or wall sections.
 2. An insulation floortile covering according to claim 1 in which said water-resistant floortiles are molded with said studs, legs or wall sections integraltherewith and provide said air gap space network therebetween.
 3. Aninsulation floor tile covering according to claim 1 in which saidwater-resistant studs, legs or wall sections are integral to a sheet ofmolded, water-resistant plastic material which is assembled to a backingto form said water-resistant plastic floor tiles.
 4. An insulation floortile covering according to claim 1 in which said plastic floor tilescomprise complementary edge means for engaging each other when saidtiles are abutted.
 5. An insulation floor tile covering according toclaim 4 in which said complementary engagement means comprise tongue andgroove means.
 6. An insulation floor tile covering according to claim 1in which the plastic floor tiles are molded fromacrylonitrile-butadiene-styrene(ABS), polyvinyl chloride, polyethylene,polypropylene or polycarbonate.
 7. An insulation floor tile according toclaim 1 having a thickness of {fraction (5/16)}″ to 1½″.
 8. Aninsulation floor tile covering according to claim 1 in which saidthermal air gap space provides a thermal break between the surface ofthe concrete floor and the upper surface of the tile.
 9. An insulationfloor tile covering according to claim 1 in which the plastic floortiles are made from an insulation material which resists heatconduction.
 10. An insulation floor tile covering according to claim 1in which said air gap space network is interconnected and is vented toallow water vapor to escape therefrom at the edges of the floor.
 11. Aninsulation floor tile covering according to claim 1 in which said airgap space is vented by means of a fan for exhausting water vaportherefrom to an exterior location.
 12. An insulation floor tile coveringaccording to claim 1 in which said air gap space is vented by means of afan for blowing dry air therethrough to displace water vapor therefrom.13. An insulation floor tile covering according to claim 1 in which thetiles have an upper surface having a decorative finish.
 14. Aninsulation floor tile covering according to claim 1 in which the tileshave an upper surface having carpeting preattached thereto.
 15. Aninsulation floor tile covering according to claim 1 in which the tileshave an upper surface having linoleum preattached thereto.
 16. Aninsulation floor tile covering according to claim 2 in which the tileshave an upper surface having a decorative finish.
 17. An insulationfloor tile covering according to claim 2 in which the tiles have anupper surface having carpeting preattached thereto.
 18. An insulationfloor tile covering according to claim 2 in which the tiles have anupper surface having linoleum preattached thereto.